Surgical clip applier including inserts for jaw assembly

ABSTRACT

A surgical clip applier includes a housing, a channel assembly, jaw assembly, and a first insert. The channel assembly extends distally from the housing and the jaw assembly is disposed at the distal end of the channel assembly. The jaw assembly includes a first and second jaws constructed of a first material. Each of the jaws defines a recess extending longitudinally along opposing inner surfaces thereof. The first insert is disposed in the recess of at least one of the first or second jaws. The first insert is constructed of a second material different from the first material.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. Provisional Patent Application No. 62/462,063 filed Feb. 22, 2017, the entire disclosure of which is incorporated by reference herein.

BACKGROUND Technical Field

The present application relates generally to surgical instruments. More particularly, the present disclosure relates to surgical clip appliers including inserts for a jaw assembly.

Discussion of Related Art

Surgical clip appliers are known in the art and have increased in popularity among surgeons by offering an alternative to conventional suturing of body tissues and vessels. Typical instruments are disclosed in U.S. Pat. No. 5,030,226 to Green et al. and U.S. Pat. No. 5,431,668 to Burbank, III et al. These instruments generally provide a plurality of clips which are stored in the instrument and which are fed sequentially to the jaw assembly at the distal end of the instrument upon opening and closing of the handles at the proximal end of the instrument. As the handles are closed, the jaws close to deform a clip positioned between the jaw members, and as the jaws are opened to release the deformed clip, a new clip is fed from the series to a position between the jaws. This process is repeated until all the clips in the series of clips have been used.

In the prior art, the jaw geometry design is heavily influenced by the type of material used for the jaw assembly of the surgical clip applier. The jaw assembly must be designed in a manner to appropriately close the clip over the body tissue and/or vessel. In conventional designs, the jaw assembly is fabricated from a biocompatible metal having the sufficient strength and toughness to close a clip over the body tissue and/or vessel placed between the jaw assembly without being deformed. Typically, stainless steel is used for the jaw assembly of the surgical clip applier. Stainless steel provides the necessary strength and toughness required of the jaw assembly. However, stainless steel jaw assemblies are expensive and time consuming to manufacture.

The need therefore exists for surgical clip appliers including a jaw assembly fabricated from a material that is easy and inexpensive to manufacture, but has the requisite strength and toughness for closing a clip over the body tissue and/or vessel placed between the jaw assembly.

SUMMARY

In accordance with the present disclosure, a surgical clip applier includes a housing, a channel assembly, jaw assembly, and a first insert. The channel assembly extends distally from the housing and the jaw assembly is disposed at the distal end of the channel assembly. The jaw assembly includes first and second jaws constructed of a first material. Each of the jaws defines a recess extending longitudinally along opposing inner surfaces thereof. The first insert is disposed in the recess of at least one of the first or second jaws. The first insert is constructed of a second material.

In one embodiment, the first material is a plastic and the second material is a metal. The metal may be selected from a group consisting of stainless steel, titanium alloy, and cobalt chrome alloy.

In another embodiment, the surgical clip applier includes a second insert. The second insert is configured of a third material disposed in the recess of at least one of the first or second jaws. The third material is a metal. The metal may be selected from a group consisting of stainless steel, titanium alloy, and cobalt chrome alloy.

In yet another embodiment, the surgical clip applier includes a first plate and second plate each extending longitudinally along a camming surface of each of the first and second jaws, respectively. Further, the surgical clip applier includes a drive channel strap housed within the elongated shaft. The drive channel strap engages the first and second plate.

In accordance with another embodiment of the present disclosure, a jaw assembly for application of surgical clips to body tissue includes a first jaw, a second jaw, a recess, a first insert, and a second insert. The first and second jaws are constructed of a first material. Also, the first and second jaws are movable between a space a part position and an approximated position. The recess extends longitudinally along opposing inner surfaces of each of the first and second jaws. The first and second inserts are constructed of a second material. Additionally, the first and second inserts are disposed in the recess of each of the first and second jaws, wherein each first and second insert is configured to receive a surgical clip.

In one embodiment, the first material is a plastic. The second material is a metal. The metal may be selected from a group consisting of stainless steel, titanium alloy, and cobalt chrome alloy.

In another embodiment, the jaw assembly includes a first plate and second plate each extending longitudinally along a camming surface of each of the first and second jaws, respectively.

BRIEF DESCRIPTION OF THE DRAWINGS

The present clip applier will be more fully appreciated as the same becomes better understood from the following detailed description when considered in connection with the following drawings, in which:

FIG. 1 is a perspective view of a surgical clip applier according to the present disclosure;

FIGS. 2 and 3 are top, plan views of a jaw assembly of the clip applier of FIG. 1, illustrating a closing of the jaw assembly during an actuation of the clip applier;

FIGS. 4a and 4b are an enlarged, perspective views of exemplary jaw assemblies for use in the clip applier of FIG. 1;

FIG. 5a is an enlarged view of a distal end portion of the jaw assembly of FIG. 4b illustrating an insert of the present disclosure supported in each jaw thereof;

FIG. 5b is a distal end view of the insert of jaw assembly of FIG. 5 a;

FIG. 6a is an enlarged view of a distal end portion of the jaw assembly illustrating another insert of the present disclosure supported in each jaw thereof; and

FIG. 6b is a distal end view of the insert of jaw assembly of FIG. 6 a.

DETAILED DESCRIPTIONS OF EMBODIMENTS

Embodiments of surgical clip applier in accordance with the present disclosure will now be described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical structural elements. As shown in the drawings and described throughout the following description, as is traditional when referring to relative positioning on a surgical instrument, the term “proximal” refers to the end of the apparatus which is closer to the user and the term “distal” refers to the end of the apparatus which is further away from the user.

Referring to FIGS. 1-4 b, a surgical clip applier in accordance with the present disclosure is generally designated as 100. Surgical clip applier 100 generally includes a handle assembly 102 having a housing 104. Handle assembly 102 further includes a pair of handles 106 pivotally secured to housing 104 and extending outwardly therefrom. A channel assembly 108 is fixedly secured to housing 104 and extends outwardly therefrom, terminating in a jaw assembly 200. The jaw assembly 200 includes jaws 202 a, 202 b.

Clip applier 100 includes a drive channel 110 reciprocally supported in and extending between housing 104 of handle assembly 102 and channel assembly 108. Clip applier 100 also includes a drive channel strap 112 secured to drive channel 110 so as to extend transversely thereacross. In an operation of clip applier 100, a squeezing of handles 106 causes the drive channel 110 to be moved distally from an initial position to a secondary position. As drive channel 110 is moved distally, a distal edge of drive channel 110 and/or drive channel strap 112 engages against camming surfaces 204 a, 204 b of jaws 202 a, 202 b, respectively, thus causing jaws 202 a, 202 b to approximate towards one another. The interaction between drive channel 110, drive channel strap 112 and camming surface 204 a, 204 b of jaws 202 a, 202 b will be discussed in further detail below.

A stack of surgical clips (one clip “C1” is illustrated in FIGS. 2 and 3) may be loaded and/or retained within channel assembly 108 in a manner so as to slide therewithin and/or therealong.

A complete description of the inner-workings and operation of clip applier 100 can be found in commonly-assigned U.S. Pat. No. 8,506,580 entitled “SURGICAL CLIP APPLIER” to Zergiebel et al., the entire contents of which are hereby incorporated by reference herein.

Jaw assembly 200, including jaws 202 a, 202 b, is fabricated from a biocompatible plastic. For example, jaw assembly 200 can be fabricated from polyethylene, polypropylene, polystyrene, polyester, polycarbonate, polyvinyl chloride, polyethersulfone, polyacrylate (PMMA), polysulfone, and polyetheretherketone (PEEK). Additionally, jaws 202 a, 202 b may be fabricated from any other suitable biocompatible plastic. Depending upon the selected biocompatible plastic, jaw assembly 200 may be reusable, disposable, or reposable. Fabricating jaw assembly 200 from a biocompatible plastic adds a number of benefits to clip applier 100. A biocompatible plastic jaw assembly 200 reduces the overall weight of clip applier 100 reducing user fatigue. Also, biocompatible plastic jaw assembly 200 may be completely or partially transparent (to the naked eye, to x-ray, and/or to fluoroscopes) improving user visibility at a distal end of the clip applier 100. Further, the time and cost to manufacture biocompatible plastic jaw assembly 200 will both be reduced as compared to conventional jaw assemblies manufactured entirely from stainless steel.

With reference to FIGS. 2 and 3, jaw assembly 200 may include plates 206 a, 206 b overlying and secured to respective camming surfaces 204 a, 204 b of respective jaws 202 a, 202 b. The plates 206 a, 206 b of jaw assembly 200 each have a length sufficient to be in contact with a distal end of drive channel strap 112 as drive channel strap 112 reciprocates during an actuation of clip applier 100. This placement of plates 206 a, 206 b on camming surfaces 204 a, 204 b of jaws 202 a, 202 b provides a surface on jaw assembly 200 having relatively reduced friction and increased strength for engagement of drive channel strap 112, as compared to a jaw assembly fabricated entirely from non-metallic materials or from biocompatible plastics. Additionally, this placement of plates 206 a, 206 b prevents unnecessary wear of jaw assembly 200 fabricated from biocompatible plastics.

Plates 206 a, 206 b are fabricated from a biocompatible metal. For example, plates 206 a, 206 b can be fabricated from stainless steel, titanium alloy, and cobalt chrome alloy or any other suitable biocompatible metal. Plates 206 a, 206 b may have a thickness ranging from 0.5 mm to 1.25 mm. Plates 206 a, 206 b may be secured to camming surfaces 204 a, 204 b of jaws 202 a, 202 b via overmolding, coating, adhering, or any other suitable process.

With specific reference to FIGS. 4a and 4b , jaws 202 a, 202 b are shown each having a respective recess or channel 208 a, 208 b (FIG. 4a ) extending longitudinally therealong, wherein recesses 208 a, 208 b are in opposed relation to one another. In accordance with an embodiment of the present disclosure, as illustrated in FIG. 4b , inserts 300 a, 300 b are supported in recesses 208 a, 208 b of respective jaws 202 a, 202 b.

Now referring to FIGS. 5a and 5b , inserts 300 a, 300 b each include two horizontal spaced apart wall plates 304 a, 304 b and 306 a, 306 b, respectively. Specifically, insert 300 a includes an upper wall plate 304 a and a lower wall plate 306 a, and insert 300 b includes an upper wall plate 304 b and a lower wall plate 306 b. Wall plates 304 a, 304 b and 306 a, 306 b extend the length of the recesses 208 a, 208 b, respectively.

Wall plates 304 a, 304 b and 306 a, 306 b of inserts 300 a, 300 b may have a thickness ranging from 0.5 mm to 1.25 mm. Additionally, wall plates 304 a, 304 b and 306 a, 306 b of inserts 300 a, 300 b can be of any thickness which does not compromise the required strength needed to sufficiently form clip “C1” by jaws 202 a, 202 b. Inserts 300 a, 300 b may be secured within jaws 202 a, 202 b, respectively, via overmolding, coating, adhering, or any other suitable process.

In an embodiment, inserts 300 a, 300 b are fabricated from a biocompatible metal. For example, inserts 300 a, 300 b can be fabricated from stainless steel, titanium alloy, and cobalt chrome alloy or any other suitable biocompatible metal. The inclusion of inserts 300 a, 300 b fabricated from a biocompatible metal gives the jaw assembly 200 (fabricated from a non-metal) the sufficient strength to appropriately form the clip “C1” upon the tissue and/or vessel positioned between the jaw assembly 200.

Now referring to FIGS. 6a and 6b , according to an alternative embodiment, inserts 300 a, 300 b have a substantially C-shaped transverse cross-sectional profile including a vertical wall plate 302 a, 302 b and two horizontal spaced apart wall plates 304 a, 304 b and 306 a, 306 b extending from vertical wall plate 302 a, 302 b, respectively. Inserts 300 a, 300 b each define a recess or channel 308 a, 308 b having a width “d”. As can be appreciated, width “d” is sufficiently large to allow passage therethrough of a clip “C1” (FIG. 2).

Walls 302 a, 302 b, 304 a, 304 b, 306 a, and 306 b of inserts 300 a, 300 b may have a thickness ranging from 0.5 mm to 1.25 mm. Additionally, walls 302 a, 302 b, 304 a, 304 b, 306 a, and 306 b of inserts 300 a, 300 b, respectively, can be of any thickness which does not compromise the required strength needed to sufficiently form clip “C1” by jaws 202 a, 202 b. Inserts 300 a, 300 b may be secured within jaws 202 a, 202 b via overmolding, coating, adhering, or any other suitable process.

While inserts 300 a, 300 b and plates 206 a, 206 b are shown and described herein for use with an open clip applier 100, it is contemplated and within the scope of the present disclosure that inserts 300 a, 300 b and plates 206 a, 206 b may also be included within endoscopic clip appliers having a jaw assembly fabricated from a biocompatible plastic. An exemplary endoscopic clip applier is shown and described in commonly-assigned U.S. Pat. No. 9,011,464 entitled “Self-Centering Clip And Jaw” to Zammataro, the entire content of which is hereby incorporated by reference.

It should be understood that the foregoing description is only illustrative of the present disclosure. Various alternatives and modifications can be devised by those skilled in the art without departing from the disclosure. Accordingly, the present disclosure is intended to embrace all such alternatives, modifications, and variances. The embodiments described with reference to the attached drawings figures are presented only to demonstrate certain examples of the disclosure. Other elements, steps, methods, and techniques that are insubstantially different from those described above and/or in the appended claims are also intended to be within the scope of the disclosure. 

What is claimed is:
 1. A surgical clip applier, comprising: a housing; a channel assembly extending distally from the housing; a jaw assembly disposed at a distal end of the channel assembly, the jaw assembly including: a first jaw having an inner facing surface, the first jaw defining a recess formed in the inner facing surface thereof and extending longitudinally therealong, wherein the recess of the first jaw defines a length and a width; a second jaw having an inner facing surface, the second jaw defining a recess formed in the inner facing surface thereof and extending longitudinally therealong, wherein the recess of the second jaw defines a length and a width; the first jaw and the second jaw are constructed of a first material, and the first jaw and the second jaw are movable between a spaced apart position and an approximated position; a first insert fixedly supported within the recess of the first jaw, wherein the first insert extends along the length of the recess of the first jaw, wherein the first insert has a U-shaped transverse cross-sectional profile defining a channel therein to receive a first leg of a surgical clip; and a second insert fixedly supported within the recess of the second jaw, wherein the second insert extends along the length of the recess of the second jaw, wherein the second insert has a U-shaped transverse cross-sectional profile defining a channel therein to receive a second leg of the surgical clip, the first insert and the second insert are constructed of a second material different from the first material in order to increase a strength of each of the first jaw and the second jaw to appropriately form the surgical clip.
 2. The surgical clip applier of claim 1, wherein the first material is a plastic.
 3. The surgical clip applier of claim 1, wherein the second material is a metal.
 4. The surgical clip applier of claim 3, wherein the metal is selected from a group consisting of stainless steel, titanium alloy, and cobalt chrome alloy.
 5. The surgical clip applier of claim 1, further including a first plate and second plate each supported on and extending longitudinally along an outer camming surface of each of the first and second jaws, respectively, wherein the first plate and the second plate are made of a material different than a material of the first jaw and the second jaw.
 6. The surgical clip applier of claim 5, further including a drive channel strap housed within the elongated shaft, wherein the drive channel strap engages the first and second plates.
 7. A jaw assembly for application of surgical clips to body tissue, the jaw assembly comprising: a first jaw having an inner facing surface, the first jaw defining a recess formed in the inner facing surface thereof and extending longitudinally therealong, wherein the recess of the first jaw defines a length and a width; a second jaw having an inner facing surface, the second jaw defining a recess formed in the inner facing surface thereof and extending longitudinally therealong, wherein the recess of the second jaw defines a length and a width; the first jaw and the second jaw are constructed of a first material, and the first jaw and the second jaw are movable between a spaced apart position and an approximated position; a first insert fixedly supported within the recess of the first jaw, wherein the first insert extends along the length of the recess of the first jaw, wherein the first insert has a U-shaped transverse cross-sectional profile defining a channel therein to receive a first leg of a surgical clip; and a second insert fixedly supported within the recess of the second jaw, wherein the second insert extends along the length of the recess of the second jaw, wherein the second insert has a U-shaped transverse cross-sectional profile defining a channel therein to receive a second leg of the surgical clip, the first insert and the second insert are constructed of a second material different from the first material in order to increase a strength of each of the first jaw and the second jaw to appropriately form the surgical clip.
 8. The jaw assembly of claim 7, wherein the first material is a plastic.
 9. The jaw assembly of claim 8, wherein the second material is a metal.
 10. The jaw assembly of claim 9, wherein the metal is selected from a group consisting of stainless steel, titanium alloy, and cobalt chrome alloy.
 11. The jaw assembly of claim 9, further including a first plate and second plate each supported on and extending longitudinally along an outer camming surface of each of the first and second jaws, respectively, wherein the first plate and the second plate are made of a third material different than a material of the first jaw and the second jaw.
 12. The jaw assembly of claim 11, wherein the third material is a metal. 